Dehydrated mash potato product and process

ABSTRACT

Dehydrated potato pellets are made by preparing an aqueous mixture of dried potato pieces, an emulsifier, and oil, and, optionally, a freshly cooked potato, homogenizing the mixture to produce a pumpable, flowable aqueous dispersion, mixing the dispersion with more dried potato pieces and, optionally, freshly cooked potatoes, forming the mixture into pellets, and drying them.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 11/370,480 filed on Mar. 7, 2006 (U.S. Pat. No. 8,017,173), which isa divisional application of U.S. application Ser. No. 10/821,419 filedon Apr. 9, 2004 (U.S. Pat. No. 7,026,006), which is a continuation ofU.S. application Ser. No. 10/683,572 filed on Oct. 9, 2003 (abandoned).

BACKGROUND OF THE INVENTION

Dehydrated mashed potatoes have been commercially available for manyyears. Many of these products are based on either potato flakes orpotato granules. Consumers of mashed potatoes prefer the rehydrated(reconstituted) potatoes to include soft potato lumps characteristic offresh mashed potatoes. In an attempt to duplicate the fresh mashedpotato product, potato bits (e.g., crushed dehydrated diced potatoes)have been added to potato flakes or granules or a puree mix. However,mashed potatoes produced from such mixtures include firm, not fullyrehydrated, potato chunks rather than the soft lumps. Moreover, therehydration preparation time is substantially extended to reconstitutethe potato pieces.

Various methods have been suggested for making quick-reconstitutingdehydrated mashed potatoes. For Example, Mathias, et al, U.S. Pat. No.3,809,758 discloses a method of making clusters of dehydrated potatoagglomerates by contacting a bed of dehydrated potatoes with an aqueousbinding solution containing milk solids to form clusters which aresubsequently dried.

Rainwater, et al U.S. Pat. No. 3,764,716 discloses a process forproducing a dehydrated mashed potato product from incompletely peeledand trimmed potatoes, including the steps of mashing, slurrying,screening, and dehydration.

Beck, et al U.S. Pat. No. 3,459,562 discloses a process for productionof instant mashed potato products of varied bulk densities from a foamedslurry of cooked potato solids.

Beck, U.S. Pat. No. 3,458,325 discloses a process for production ofinstant mashed potato products by mixing potato granules and flakes,moistening to form a damp intermediate, and drying.

Rainwater, et al U.S. Pat. No. 3,407,080 discloses dried agglomeratedfoods and the process for manufacturing. The process includes the stepsof foaming a slurry, extruding the foam to form discrete pieces, coatingthe foam pieces with dry particles, and drying.

Beck, et al U.S. Pat. No. 5,292,542, discloses a process for makingdehydrated mashed potato products by mixing potato flakes with water tomoisten, reducing the product temperature and holding for a time longenough to effect retrogradation of free starch, reducing the size of thepotato flakes, and drying.

One method to produce dried potato mash which is not directly based onflakes or granules is proposed in Grufstedt, et al. publication WO85/03204. It is not believed that this process was ever commercialized.The Grufstedt publication disclosed precooking, cooling and cookingpotatoes as performed in producing potato mash powder (potato granules)and potato mash flakes. Then, the product is disintegrated by strainingthrough a screen device or through a perforated plate, followed bydrying and commination. The publication discloses reconstitution inboiling water, which suggests a temperature intolerance forreconstitution. This water temperature intolerance is an undesirabletrait for a commercial dehydrated mashed potato product.

Another dehydrated mash potato product which has been commercialized isdisclosed in U.S. patent application Ser. No. 10/245,841 filed Sep. 17,2002. entitled Dehydrated Mash Potato Product & Process.

SUMMARY OF THE INVENTION

In one embodiment of the present invention, dehydrated potato pelletsare made by a method comprising the steps of

-   -   (a) preparing an aqueous mixture of a first portion of dried        potato pieces, said mixture including an emulsifier, water, and,        optionally, a first portion of comminuted freshly cooked potato,    -   (b) homogenizing the mixture of step (a) to produce a homogenate        comprising potato and emulsifier uniformly dispersed in a        pumpable, flowable aqueous dispersion,    -   (c) mixing the homogenate of step (b) with a second portion of        dried potato pieces,    -   (d) forming the mixture of step (c) into pellets, and    -   (e) drying said pellets.

Another embodiment of the invention comprises dried potato pelletsrehydratable into mashed potato, said pellets comprising at least about2% oil uniformly dispersed within said pellets.

Another embodiment of the invention comprises a homogenized pumpable,flowable stable aqueous dispersion comprising uniformly dispersed andsubstantially completely rehydrated, dried potato pieces, emulsifier andoil.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

As an overview, the present invention relates to a method for makingdehydrated potato pellets comprising the steps of preparing an aqueousmixture of a first portion of dried potato pieces, said mixtureincluding an emulsifier, water, and, optionally, a first portion ofcomminuted freshly cooked potato. Then the mixture is homogenized to apumpable, flowable aqueous dispersion. The homogenate is mixed with asecond portion of dried potato pieces and formed into pellets and dried.The invention can utilize one of three different process options,depending on the desired feedstock and finished-product texture.

The first option utilizes dry potato ingredients (i.e. no freshpotatoes) as a feedstock to the process wherein the finished rehydratedready-to-eat mash exhibits a smooth texture without significant lumps.In this process, ingredients are homogenized, mixed, formed intopellets, and dried.

A second option utilizes fresh potato as well as dry potato ingredientsas a feedstock to the process wherein the finished rehydratedready-to-eat mash exhibits a smooth texture without significant lumps.In this process, ingredients are homogenized, mixed, formed intopellets, and dried.

A third option utilizes fresh potatoes as well as dry potato ingredientsas a feedstock to the process wherein the finished rehydratedready-to-eat mash exhibits a texture with lumps similar to mash madefrom fresh potatoes. In this process, the prepped fresh potatoes aresubdivided into two streams wherein one stream is optionally riced andresponsible for providing lumps. The second stream is homogenized. Bothstreams are subsequently recombined, mixed with additional ingredients,formed into pellets, and dried.

For the second and third options using fresh potatoes, partially orfully peeled fresh potatoes are cooked, optionally riced, and separatedinto two fractions (with one fraction being homogenized with additionalingredients), mixed with additional ingredients, formed, and dried. Anycommercially available potato variety may be used. Such varietiesinclude Russett Burbank, Russet Norkotah, Shepody, Ranger, Umatilla,Alturas, Cal White, Norchip, Norgold, Snowden, Ida Rose, and Cal Rose.

Partially to fully peeled fresh potatoes can be cooked and cooled. Theprocess of cooking and cooling is well known in producing potatogranules or potato flakes. Such methods are disclosed in Talburt andSmith, Potato Processing (4^(th) Ed.).

Fresh potatoes are typically subjected to a variety of unit operationsthat may include washing, derocking, peeling, trimming, and cutting asdisclosed in Potato Processing. Thereafter, the potatoes may besubdivided as by cutting into slabs or other smaller forms such asslices, dices, shreds, or strips prior to cooking.

In one embodiment using freshly cooked potatoes, the potatoes are cutinto ⅝- to ¾-inch thick slabs that may be cooked in order to inactivateenzymes, swell the potato cells, soften intercellular bonds and the likeas performed in the flake and granule industry. The thinner the potatopieces, the shorter the cook time. The cook time and amount of steamused will depend on many factors such as the potato variety, age, piecesize, loading and type of cooking equipment. Suitable commercial cookconditions for potato slabs using saturated steam cooking at atmosphericpressure are from 20 to 90 minutes, preferably 30 to 60 minutes. Coolingunder pressure will reduce the cooking time. As disclosed, cooking andmashing may be accomplished with a single unit such as, a twin-screwcooker with a discharge auger with a mashing plate at the discharge end.During cooking, the starch cells preferably are fully swollen but withminimal free starch. If the potato is overcooked, the cells tend toburst producing free starch. Conversely, if the potatoes areundercooked, the derived potato product will not rehydrate adequately toprovide a product that simulates fresh mashed potatoes. Cooking ispreferably sufficient to deactivate peroxidase and to leave lumps in therehydrated mash while permitting rehydration within about 5-15 minutes.

At this point, if lumps are desired, the potatoes are subdivided intotwo streams. The first stream may be sent to a cooling step ormaintained at a hot temperature; this material will be optionally ricedand be responsible for providing lumps. The second stream will bereferred to as the homogenate; this material is responsible forproviding the adhesive material that will bind the product togetherthrough the extruder, dryer, and in the finished product. In addition,the homogenate will provide the smooth texture component to the mash.

Regarding the first of the subdivided streams, the potatoes may eitherbe cooked and then optionally riced or cooked-cooled-riced. In oneoption, potatoes may be cooled, e.g., using water with an inlettemperature of about 15° C. and an outlet temperature of about 24° C.for a time of 12 minutes. The cooling step serves to retrograde orharden starch cells, stop the cooking process, and maintain cellstructure—both intercellular and intracellular—providing a group ofcells that is distinguished as a lump or bit with a bite which can bevaried from soft to firm in the finished mash. If desired, the potatoesmay be cycled through a second cook and cool operation. This serves thepurpose of additionally hardening the starch cells. Proper cooling canbe important to the creation and maintenance of lumps with a firmer bitein the finished products. An optional next stage of the process iscomminuting the fresh potato. Comminuting as defined herein is similarto the mashing term used in the potato industry in which the cookedpotato products are forced through a “masher” or “ricer” on the order of⅜-inch opening in circular holes or slots to provide a mixture of chunksand mash. Mashing is described on pages 575-576 and illustrated in FIG.13.7 of Potato Processing. Commination also includes non-comminativepressing that results in a size reduction. As disclosed, cooking andmashing may be accomplished with a single unit such as, a twin-screwcooker with a discharge auger with a mashing plate at the discharge end.This fraction of the potato stream is referred to as the comminutedfresh potatoes.

The terms “comminuting”, “ricing” and “mashing” and variants of theseterms are used interchangeably herein. Comminuted potatoes as usedherein refer to comminution of cooked potatoes and excludes comminutionof previous dehydrated potatoes. Comminution can be accomplished priorto homogenization and mixing such as by ricing or mashing.Alternatively, comminution may be accomplished by the use of appropriateconditions during homogenization or mixing after homogenization.

Regarding the second of the subdivided streams, the potatoes may behomogenized with additional ingredients. As used herein, homogenizationrefers to the reduction of the particle sizes of the potatoes, andblending with additional ingredients in order to create a mixturecomprised primarily of small particles that exhibit smooth texture, aswell as, uniform texture and composition. Any equipment in the art thatachieves these product characteristics may be used such as mixers,homogenizers, macerators, etc. However, a preferred means of achievingthe end result is to use a blender or homogenizer, e.g. BreddoLikwifier™ and/or a Ross™ Inline Mixer, in conjunction with aTri-clover™ pump. In a preferred method, homogenate is produced in thefollowing manner: Into a Breddo Likwifier is placed fresh cookedpotatoes or dried potatoes, water, oil, titanium dioxide, emulsifiersand sulfite. Fresh potatoes from the homogenate, on a bone dry solids(BDS) basis of the finished product can range from 20% to 85% of thefinished product solids, but more preferably from 22% to 55% of thefinished product, and most preferably from 25% to 45% of the finishedproduct. When dry potato pieces are used in the homogenate, the BDScontent of the homogenate potato pieces in the finished product suitablycan range from 1% to 80%, more preferably from 5% to 50%, and mostpreferably from 10% to 40% of the finished product solids.

Oil is a preferable ingredient added to the product prior tohomogenization. It can be used at a total level of from 0% to 20%,preferably 2% to 15%, or 4% to 12%, of the finished product (BDS Basis),more preferably 6% to 10% of the finished product. Oil serves to assistwith flavor dispersion, flavor release, rehydration rate control,elasticity of moist pellet or pellet right out of the extruder,emulsifier dispersion, and controlling the rate and manner in which theemulsifier or emulsifiers react. Suitable oils include food gradevegetable or other types of oils, including soybean oil, coconut oil,cottonseed oil, sunflower oil, palm oil, canola oil, corn oil, oliveoil, rendered fat, or combinations thereof. A preferred oil is coconutoil with a melting point of about 32° C. Suitably the oil is mixed withthe emulsifier prior to homogenization. Preferably, the oil is added ina quantity so that at least 2.0%, 2.5%, 3.0%, 3.5%, 4.0%, 4.5%, 5.0%,6.0% or more of the oil is uniformly dispersed in the pellets afterdrying. The term “uniformly dispersed” excludes enrobing of the pelletswith oil. However, the total oil content can be increased by enrobing orby adding the oil in dry form.

Emulsifier also is added prior to homogenization. Emulsifier serves thefunctions of a surfactant or HLB (Hydrophilic/Lipophilic Balance) andstarch crystal stability and starch complexing and instantizing. Any ofthe well-known food grade emulsifiers may be used. Suitable emulsifiersinclude monoglycerides, mixtures of mono- and diglycerides, andderivatives thereof, including DATEM (diacetyl tartaric acid esters ofmono- and diglycerides). One such additive that is particularlyadvantageous is a lubricant, e.g., an emulsifier and/or fat that can beadded to provide lubricity to reduce the shear on the potato cellspassing through the ricing barrier. Emulsifiers such as mono- anddi-glycerides (e.g., Dimodan PV manufactured by Danisco USA Inc.),and/or DATEM (e.g. Panodan 150K manufactured by Danisco USA Inc.) inaddition to serving as lubricants, also assist in complexing of freestarch to aid in the prevention of product stickiness.

Mono- & diglycerides derived from either vegetable or animal fatstypically consist of a mixture of predominantly saturated acyl fattyacids including lauric, palmitic, stearic, myristic in combination withunsaturated acyl fatty acids, including oleic, eladic, linoleic andcombinations thereof. Mono- & diglycerides typically have amonoglyceride content greater than 40%, preferably greater than 60% andmost preferably greater than 90%. In the production of monoglycerides, atriglyceride normally is reacted with glycerol to form a mixture of mono& diglycerides. This process can be carried further to isolate or toconcentrate the monoglyceride fraction by molecular distillation. Theremaining components, predominantly di & triglycerides are typicallyrecycled back to the reaction with glycerol to make additionalmonoglyceride.

Thus, it is advantageous to add the lubricants and specificallyemulsifiers to the potato mash prior to homogenizing. Preferredemulsifiers used in this invention include Dimodan PV and Panodan 150K.Other suitable emulsifiers include sodium or calcium stearoyl lactylateand lecithin. In general, the emulsifiers function in the mannerdescribed in Food Product Design, October 1995, “EmulsifierApplications, Design Elements”, Scott Hegenbart, Ed. The emulsifier(s)suitably are added in an amount to constitute a percentage of thefinished product of 0.005% to 5%, preferably 0.01% to 2%, and morepreferably 0.02% to 0.5% on a dry solids (BDS) basis. Emulsifier may beadded as independent ingredient or as a component of another ingredientsuch as flakes or granules.

Titanium dioxide (TiO₂) can be added to the homogenate in a dry form, orin an aqueous dispersion.

Ingredients are suitably fed on a continuous basis into a homogenizerset at low speed within the foregoing conditions and held preferably for1 to 60 minutes, and more preferably for 10 to 40 minutes. Individually,the Breddo Likwifier and the Ross Inline Mixer can function as ahomogenizer, causing homogenization of ingredients and mechanicalbreaking of cooked and swollen potato cells resulting in an emulsionstable enough to deliver the dispersed ingredients in the homogenate tothe dry ingredients in the mixing step. The Breddo Likwifier and theRoss Inline Mixer are used in combination for better control ofhomogenate properties and thereby the intermediate and finished product.

The homogenate is then fed through a pump which meters the flow rate toa Ross Inline Mixer. The Ross Inline Mixer is used to fine-tune thedegree of shear imparted to the homogenate.

The degree of homogenization is dependent on the condition of theincoming potato source, the shape of the formed piece, the dryer anddryer conditions, and the desired attributes of the finished product.When the potato is minimally cooked or cooked to a firm state, such aswhen lumps and fresh feedstock are desired, or dry potato pieces areused, then the degree of shear caused by the homogenizing process willbe fairly high. Typical cook conditions for a product with lumps andusing fresh feedstock would preferably be 10 to 60 minutes, morepreferably 15 to 40 minutes and most preferably 20 to 30 minutes withsaturated steam at atmosphere pressure.

Typical process conditions for a product made from dry potato pieces(without fresh potatoes) would retain the same conditions within thehomogenizer. If no lumps and fresh feedstock or a high degree of cook isused then the desired degree of shear caused by homogenization can below.

The degree of homogenization also controls the stickiness of the finalrehydrated mash, more stickiness is achieved by increasing the degree ofshear during homogenization and less is achieved by decreasing thedegree of shear during homogenization. Stickiness can also be controlledby the level, type and time of introduction of emulsifiers used in thehomogenate and in the mixer. Balancing the degree of cook with the shearand emulsifier addition allows the ability to balance opposingattributes, in particular, elasticity (or in other words stickiness) ofthe wet pellet, where as much stickiness as possible is desired in orderfor the pellet to survive handling and drying, but where minimalstickiness is desired in the finished product. This has beenaccomplished by shearing the potato cells, allowing the interstitialfluids (containing amylose, very sticky material, and amylopectin,moderately sticky material) to flow out and act as an adhesive.

Expanding on the foregoing description of the emulsifier and itsfunctioning, emulsifier, e.g. mono- and diglycerides, willpreferentially react with the amylose, (which is very sticky andcontributes to the stickiness in the finished product), then it willreact with the amylopectin (which is sticky, but not as sticky asamylose,) and then with the oil. Amylose provided by the shearing ofpotato cells, both intra and interstitial cell fluids, and the amylosecreated by the shearing of amylopectin is controlled by providing alimited amount of emulsifiers at the time and shortly after shearing.Reducing the level of amylose will reduce the level of stickiness in thefinished product, and conversely, increasing the level of amylose willincrease the level of stickiness in the finished product. Controllingthe amount of mono and diglycerides will control the amount ofamylopectin that will be affected, or made non-sticky, providingadhesive material and elasticity for the pellet in the moist form, whilereducing it's tendency to case harden resulting in improved rehydrationcharacteristics. Additionally, some of the mono and diglycerides act assurfactants for the oil within the homogenate. The results are a pelletthat is elastic enough to be handled and dried in the wet form andrehydrates easily into a mash with minimal stickiness. If DATEM is usedas the emulsifier, it will first act as a surfactant for the oil andthen as a starch stabilizer by combining with the amylose and then theamylopectin with similar and complimentary results as those statedabove.

The potatoes may or may not be cooled, prior to this step. In thepreferred embodiment, hot potatoes are not cooled and are made into ahomogenate by blending with water and a heated oil premix (to whichmultiple ingredients have been mixed-in: e.g., emulsifier, antioxidant,and caseinate), and with subsequently added ingredients (such as sulfiteand titanium dioxide).

Some of the additives used provide functional properties well known inthe art. For example, a variety of additives known in the industry forincorporation to mash before drying may be employed such as disclosed onpages 576-579 of Potato Processing with respect to potato flakes.Similar additives may be used in the present process.

Antioxidant provides protection against oxidative rancidity development,and although a number of antioxidants might be considered for thispurpose (e.g. BHT, BHA, TBHQ, rosemary, etc), it has been found that BHTprovides a level of protection for the product of this invention whenpresent in the finished dehydrated product at a level of between about 1to 25 ppm.

The use of sulfite in potato products is well known in the art and isdisclosed in Potato Processing.

Caseinate may be added for the purposes of flavor, at a level of about1%.

Water is added to the mixture in a sufficient amount to provide apumpable, flowable mixture, and to maintain correct aqueous phase forthe emulsifier(s), maintaining starch structure or hydration andhydrating the TiO₂. Suitably, sufficient water is added so that thewater content of the homogenate at least 50% (w/w), preferably 72%, andmore preferably 80% to 85%. As used herein, water content includes allwater in the homogenate whether added in liquid form or as part of asolid ingredient such as potato solid. Temperature of the added waterpreferably is at least 37° C., but more preferably 60° C., and mostpreferably 76° C.

If oil is used in a premix to be added to the homogenizer, sodiumcaseinate can be stirred into a heated oil blend for a minimum of3^(1/2) minutes in order to drive off the “Cardboard or Drier” notes.The conditions of homogenization can be important to the finishedproduct quality with the degree of shear controlling the level of “glue”or free starch and thereby the pellet formation and pellet attributes inthe dryer and product attributes of the rehydrated mash. In addition,homogenization of the oil, emulsifiers, and free starches are criticalto the speed and manner in which the finished product hydrates,resulting in greatly improved mixing characteristics. Homogenization ofthe free starches, oil, and emulsifiers in the proper form control thewater activity and bonding of free starches in such a manner as to allowdry flavors, or encapsulated flavors, to be further encapsulated andthereby extending the shelf life of the product. Additionally, theoil-emulsifier system binds the flavor within the reconstituted mash,changing the degree and speed in which a flavor releases.

The homogenate from this unit operation should exhibit pumpable,flowable characteristics and wherein the solids and oil will not easilyseparate from the dispersion. As used herein, the term “pumpable” isused in a manner well known in the art, e.g. it is capable of beingpumped through pumps, e.g. such as positive displacement pumps thatimpart minimal shear, e.g. piston pumps. As used herein, “flowable” isused in a manner well known in the art, e.g. it is capable of movingand/or changing form when acted upon by forces, such as by gravity. Onemeasure of flowability is viscosity, for example, as measured on aBostwick Consistometer wherein suitable viscosities for this viscousfluid measured between 53 and 63° C. e.g., are in the range of betweenabout 6 to 16 centimeters.

At this point, the freshly cooked potatoes may be mixed with additionalingredients such as dry potato ingredients (“potato pieces”), caseinate,salt, and flavors. As used herein, the term “potato pieces” includespreviously dried potato ingredients such as potato flakes, granules,flanules, Potato Pearls®, Potato Buds™, Potato Pearls Excel® and potatoflours. The potato pieces may also include dehydrated chunks from potatoslices, dehydrated potato dices, dehydrated potato shreds wherein theyare preferably rehydrated prior to extrusion, e.g. before or duringhomogenization or during or after mixing with the homogenate, preferablyincluding dry potato granules.

The adhesive material in the process is controlled by the level ofmixing during homogenizing. Over-mixing the potato pieces, e.g.granules, and homogenate can produce more adhesive material than isdesired resulting in an unacceptable product. Under-mixing results innon-uniform dispersion of the added ingredients. Preferably, mixing isjust long enough to uniformly blend the homogenate/granule mixture withthe fresh potatoes, salt and flavor.

After mixing, the moist potato mixture is formed by the application ofpressure such as by extrusion, e.g., by urging or forcing the materialthrough multiple openings of a forming barrier to create formed moistpotato pellets that are thereafter dried. During forming, the moistpellets formed tend to assume the cross-sectional shape of the openingsor perforations in the forming device. As used herein, the term pelletsincludes pieces of any shape geometry, such as cylinders, noodles,spheres, ovoids, strips, dice, and the like. In a preferred embodiment,a low-pressure extruder with a multiplicity of holes ranging in diameterfrom about 1.6 mm to 9.5 mm and preferably 4.0 mm to form the pellets; acutoff wire or knife can optionally be used at this point to controlpellet length. If desired, the shapes of the openings may be any otherconfiguration such as rectangular, hexagonal, oblong, oval, crescent, orthe like. The openings are sized and with adequate open area to minimizethe pressure to force the potatoes through the openings which mightthereby rupture potato cells releasing excessive potato starch. Otherforming devices may be employed such as ricers, sheeter-cutters, rollformers, and the like. An important advantage of forming is to produce adried product which reconstitutes into a fresh mashed potato-likeproduct with a desired amount of soft lumps as described hereinafter.Any pressure application that accomplishes this is encompassed by theterm “forming.”

The proportions of potato solids vary depending on the type of product,e.g. (1) one formed without fresh comminuted potato additions, (2) onewith such addition but without lumps from fresh potatoes, and (3) onewith lumps from fresh potatoes.

Referring to (1), (2) and (3), previously dehydrated potato pieces areadded both prior to homogenization and after homogenization. Preferably,the ratio of potato pieces after and before homogenization is from about99:1 to 0.25:1, more preferably about 19:1 to 1:1, still more preferablyabout 9:1 to 1.5:1. If flakes are used as the majority of potato pieces,the range tends to be higher while if granules are used as the majority,the range tends to be lower.

Referring to (2) and (3), the ratio of potato pieces to potato fromfresh comminuted potatoes BDS suitably is from about 4:1 to 0.2:1preferably about 3:1 to 1.22:1.

Referring to (3), the ratio of comminuted fresh potatoes which bypassesthe homogenizer (and thus contributes to lump formation) to thecomminuted fresh potatoes added to the homogenizer suitably is fromabout 11:1 to 0.6:1, preferably about 9:1 to 3:1 and more preferablyabout 8:1 to 4.5:1.

The dried (packout) pellets suitably contain about 70 to 99% or more,preferably about 15% to 97% and more preferably 80% to 95% BDS of potatopieces when no comminuted fresh potato is used. Suitably, about 20% to85%, and preferably 25% to 45% of the packout is from comminuted freshpotato regardless of the amount of fresh potato which bypasses thehomogenizer. If there is a bypass of the homogenizer to form lumps,suitably about 70% to 95%, preferably 80% to 90%, of the comminutedfresh potato is the lump producing bypass fraction.

After forming, the product may be dried under conventional conditions,for example using fluid bed dryers and/or traveling belt dryers. Dryingtypically occurs in hot-air forced-convection dryers wherein the productmoisture is reduced from about 47%-65% moisture (w/w) down to 5%-10%(w/w) moisture, and more preferably 7% to 9%. Suitable conditions are asfollows: The initial drying steps can be conducted in a conventionalfluid-bed dryer, e.g., with initial-stage dryer air temperatures ofapproximately 120° C., and finish-drying at approximately 65° C. Drytime can vary from between about 10 and 60 minutes depending on manyfactors such as drier design, air temperature, air velocity, airhumidity, product moisture content, etc.

The product made by the foregoing process has desirable characteristicsmimicking fresh mashed potatoes upon reconstitution in hot water. Thus,a mashed potato product reconstituted in water at 82° C. under lightstirring conditions includes a quantity of soft lumps, when desired,that are very similar to lumps found in fresh mashed potatoes.

Another advantage of the product of the present invention is its rapidreconstitution in water to a ready-to-eat mashed potato product. Thus,at a water temperature of 82° C. under light stirring conditions, theproduct can be made into a mashed potato with soft lumps in less thanabout 15, 10, 7, 5, 3, 1 minutes or less.

A further advantage of the product is its wide range of acceptable watertemperatures for rehydration. The span of this water temperature rangeis best seen when compared to other conventional dehydrated mashedpotato products. Thus, the dehydrated product of the inventionreconstitute acceptably with rehydration water temperatures of betweenabout 54° C. and boiling. In comparison, flake-based and granule-basedproducts exhibit a narrow range of water temperature for rehydration.The tolerance of water temperature for rehydration for flake-basedproducts is in the range of about 38° C. to about 77° C. The toleranceof water temperature for rehydration for granule-based products is inthe range of about 82° C. to boiling. Thus, the product of thisinvention spans the water rehydration temperature tolerance rangebetween flake-based and granule-based products, and overlaps the waterrehydration temperature tolerance portions of both flake-based andgranule-based products. This is an important characteristic of theproduct for foodservice sales because a hot water dispenser is typicallyavailable, and the water from these dispensers usually ranges from 71°C. to 93° C.

A further advantage of the product is that its flavor system whenincorporated in the dough is uniformly distributed throughout theproduct prior to extrusion and drying and so uniformly distributed inthe dried pellets. Such uniformly distributed flavors are significantlymore stable than the flavor held separate or stored with the pellets. Inthe latter case, the starches from the potatoes, both amylose andamylopectin in conjunction with the oil and emulsifiers appear to form asecond layer of encapsulation to the added dry flavor. This has resultedin improved shelf life of the dehydrated product, i.e. product stored at21° C. for 12 months is judged equal to a frozen control. Additionally,when oil is added to the homogenate and flavor to the dough and extrudedtogether the oil and flavor are uniformly distributed and flavor thecharacter and release rate of flavor in the rehydrated mash is improved.

Additionally, the product has advantages for mixing tolerance. Theproduct and water can be lightly stirred or machine mixed with favorableresults. In comparison to prior art, potato-flake-based products can behand-mixed, but when machine-mixed, they tend to become sticky orgelatinous. On the other hand, granule-based products are typicallymachine-mixed for the best results.

In order to illustrate the present invention, examples of its practiceare given.

EXAMPLE 1

This Example illustrates the present invention to produce a dehydratedmashed potato product (with lumps) made with a fresh potato component.

1. Russet Norkotah potatoes are washed to remove soil and to reduce themicrobiological load. These potatoes are then peeled and cut into ¾-inchslabs in an Urschel Model B cutter.

2. Pieces are then cooked in saturated steam at atmospheric pressure for14 minutes, cooled in water for 12 minutes (water temperature at 60°F.), and then riced through ⅜-inch circular holes. The product from thisunit operation is then subdivided into two separate fractions, to beprocessed separately.

3. The first fraction of product from step 2 is referred to as the ricedpotatoes.

4. The second fraction of product from step 2 is used to make ahomogenate by the following procedure:

-   -   a. Coconut oil is heated to 43° C.    -   b. 36.156 grams (i.e., 10% w/w) of the preheated oil from the        preceding step is transferred into a separate vessel, and a        total of 2.8704 grams of emulsifiers (mono & diglycerides and        DATEM) are mixed in.    -   c. A blend of oil and emulsifiers is prepared by combining 10%        (w/w) of the oil blend from step 4 b with 90% of the original        oil from step 4 a.    -   d. 0.20 grams of BHT are added to the oil blend from step 4 c        and stirred for 10 minutes until the mixture is homogeneous.    -   e. To 361.56 grams of this heated oil, 54.84 grams of sodium        caseinate are added and stirred for an additional five minutes.    -   f. Into each of 3 individual Waring Heavy Duty Laboratory 4        Liter Blenders, the following ingredients are placed: 1315.80        grams of riced potatoes, 1105.25 grams of water (at a minimum of        76° C.), 5.13 grams of titanium dioxide, and 361.56 grams of the        oil blend (from step 4 e). The mixture is blended at the high        setting for 12 seconds. Following this, 3.29 grams of sodium        bisulfite are added and the blender “pulsed” for one second.        This final material is referred to as the homogenate.

5. The product is then mixed by the following procedure:

-   -   a. Into a Hobart Mixer, Model T-801 with paddle attachment,        8636.33 grams of dehydrated potato granules are added and        blended for 10 seconds on Speed 1 while all the Homogenate from        the 3 blenders of step 4 f is added.    -   b. Into a Hobart Mixer, Model V-1401 UH, 26150.16 grams of riced        potatoes are added from step 3, as was all of the        Granule/Homogenate mixture from step 5a. This is mixed with a        paddle for 5 seconds. A flavor blend (e.g., salt, butter, and        dairy flavors) is then added to the mixer and blended for an        additional 5 seconds.

6. Pellets are then formed in a low-pressure extruder through amultiplicity of circular extrusion holes of 5/32-inch diameter. Pelletlength is controlled with cutoff knives, which form pellets of randomlength.

7. Pellets are then dried in a laboratory-scale fluid-bed dryer for 16minutes at 93° C. air temperature and an additional 16 minutes at 66° C.air temperature. The final moisture content of the pellets is 7%.

To the product made by the above process, hot water is added and theproduct is then mixed with a wire whisk and is ready to serve at 5minutes reconstitution time. The taste and texture is similar to freshcooked mashed potatoes.

EXAMPLE 2

This Example illustrates the present invention to produce a dehydratedmashed potato product (without lumps) made with a fresh potatocomponent.

1. Russet Burbank Potatoes are washed to remove soil and to reduce themicrobiological load. These potatoes are then peeled and cut into ⅝-inchslabs in an Urschel Model B cutter

2. Pieces are then cooked in saturated steam at atmospheric pressure for18 minutes and then riced through ⅜-inch circular holes.

3. The product from step 2 is used to make a homogenate by the followingprocedure:

-   -   a. Coconut oil is heated to 43° C.    -   b. 36.156 grams (i.e., 10% w/w) of the preheated oil from the        preceding step are transferred into a separate vessel, and a        total of 2.8704 grams of emulsifiers (mono & diglycerides and        DATEM) are mixed in. The oil is heated to 79° C. and        subsequently cooled to 43° C.    -   c. A blend of oil and emulsifiers is prepared by combining 10%        (w/w) of the oil blend from step 4 b with 90% of the original        oil from step 4 a.    -   d. 0.02 grams of BHT are added to the oil blend from step 4 c        and stirred for 10 minutes until the mixture is homogeneous.    -   e. To 361.56 grams of this heated oil, 54.84 grams of sodium        caseinate are added and stirred for an additional five minutes.    -   f. Into each of 9 individual Waring Heavy Duty Laboratory 4        Liter Blenders, the following ingredients are placed: 1315.80        grams of riced potatoes, 1105.25 grams of water (at a minimum of        76° C.), 5.13 grams of titanium dioxide, and 361.56 grams of the        oil blend (from step 4 e). The mixture is blended at the high        setting for 14 seconds. Following this, 3.29 grams of sodium        bisulfite are added and the blender “pulsed” for one second.        This final material is referred to as the homogenate.

4. The product is then mixed by the following procedure:

-   -   a. Into a Hobart Mixer, Model T-801 with paddle attachment,        12020 grams of dehydrated potato granules are added and blended        for 10 seconds on Speed 1 while all the homogenate from the 9        blenders of step 4 f is added.    -   b. A flavor blend (e.g., salt, butter, and dairy flavors) is        then added to the mixer and blended for an additional 5 seconds.

5. Pellets are then formed in a low-pressure extruder through amultiplicity of circular extrusion holes of 5/32-inch diameter. Pelletlength is controlled with cutoff knives, which form pellets of randomlength.

6. Pellets are then dried in a laboratory-scale fluid-bed dryer for 16minutes at 93° C. air temperature and an additional 16 minutes at 66° C.air temperature. The final moisture content of the pellets is 7%.

To the product made by the above process, hot water is added and theproduct is then mixed with a wire whisk and is ready to serve at 5minutes reconstitution time. The taste and texture is similar to freshcooked mashed potatoes.

EXAMPLE 3

This example illustrates the present invention to produce a dehydratedmashed potato product (without lumps) made with only dehydrated (i.e.,no fresh) potato components.

1. A homogenate is prepared by the following procedure:

-   -   a. Coconut oil is heated to 43° C.    -   b. 36.156 grams (i.e., 10% w/w) of the preheated oil from the        preceding step are transferred into a separate vessel, and a        total of 2.8704 grams of emulsifiers (mono & diglycerides and        DATEM) are mixed in. The oil is heated to 79° C. and        subsequently cooled to 43° C.    -   c. A blend of oil and emulsifiers is prepared by combining 10%        (w/w) of the oil blend from step 4 b with 90% of the original        oil from step 4 a.    -   d. 0.02 grams of BHT are added to the oil blend from step 4 c        and stirred for 10 minutes until the mixture is homogeneous.    -   e. To 361.56 grams of this heated oil, 54.84 grams of sodium        caseinate are added and stirred for an additional five minutes.    -   f. Into each of 9 individual Waring Heavy Duty Laboratory 4        Liter Blenders, the following ingredients are placed: 250 grams        of granules, 2171.05 grams of water (at a minimum of 76° C.),        5.13 grams of titanium dioxide, and 361.56 grams of the oil        blend (from step 4 e). The mixture is blended at the high        setting for 30 seconds. Following this, 1.65 grams of sodium        bisulfite are added and the blender “pulsed” for one second.        This final material is referred to as the homogenate.

2. The product is then mixed by the following procedure:

-   -   a. Into a Hobart Mixer, Model T-801 with paddle attachment,        12019.91 grams of dehydrated potato granules are added and        blended for 10 seconds on Speed 1 while all the Homogenate from        the 9 blenders of step 4 f is added.    -   b. A flavor blend (e.g., salt, butter, and dairy flavors) is        then added to the mixer and blended for an additional 5 seconds.

3. Pellets are then formed in a low-pressure extruder through amultiplicity of circular extrusion holes of 5/32-inch diameter. Pelletlength is controlled with cutoff knives, which form pellets of randomlength.

4. Pellets are then dried in a laboratory-scale fluid-bed dryer for 16minutes at 93° C. air temperature and an additional 16 minutes at 66° C.air temperature. The final moisture content of the pellets is 7%.

To the product made by the above process, boiling water is added, andbriefly stirred. After 5 minutes, it is then machine-mixed for 9 secondsat high speed in a Hobart mixer. The taste and texture is similar tofresh cooked mashed potatoes.

1. Dehydrated potato pellets, rehydratable into a mash having a lumpytexture, made by a method comprising the steps of: (a) homogenizing amixture comprising oil, emulsifier and at least one of cooked potato anddehydrated potato pieces to produce a homogenate comprising potato, oiland emulsifier uniformly dispersed in a pumpable, flowable aqueousdispersion, the water content of said homogenate comprising at least 50wt % of said homogenate, (b) mixing the homogenate of step (a) withriced cooked potato and optionally dried potato pieces, (c) forming themixture of step (b) into pellets, and (d) drying said pellets to amoisture content no greater than 10 wt % said pellets comprising atleast 2% (w/w) oil uniformly dispersed therein and being rehydratable tomashed potatoes.
 2. The dehydrated potato pellets of claim 1 wherein themixing of step (b) is with riced cooked potato and dried potato pieces.3. The dehydrated potato pellets of claim 1 or 2 where at least about 2%oil is uniformly dispersed within said pellets.
 4. Dried potato pelletsrehydratable into mashed potatoes having a lumpy texture made bypressure-forming pellets from a mixture comprising (a) riced cookedpotatoes, and optionally dried potato pieces and (b) a potato homogenatecomprising at least 2% oil, emulsifier and at least one of cooked potatoand dehydrated potato pieces, wherein said potato homogenate comprisespotato, oil and emulsifier uniformly dispersed in a pumpable, flowableaqueous dispersion before being mixed with said riced cooked potatoesand the optional dried potato pieces.
 5. The dried potato pellets ofclaim 4 wherein said mixture comprises (a) riced cooked potato and driedpotato pieces and (b) said potato homogenate.